Note: Descriptions are shown in the official language in which they were submitted.
WO 2022/082303
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MODULAR MULTI-ZONE MATTRESS AND RELATED DESIGN METHOD FOR
OPTIMIZATION OF A SLEEP SURFACE
TECHNICAL FIELD
[0001] The present invention generally relates to mattresses, and more
particularly to a
modular multi-zone mattress and related techniques for designing said mattress
with an
optimized sleep surface of variable deformability.
BACKGROUND
[0002] Some ways of improving the quality of sleep include providing a modular
mattress. Modular mattresses can include several modules of mattress material
that can
be assembled to form a sleep surface.
[0003] Existing modular mattresses are designed based on general
anthropometric
knowledge including known morphotypes, such as ectomorph or mesomorph. These
modular mattresses therefore lack flexibility and precision to adapt the sleep
surface to
one mattress user specifically.
[0004] There is thus a need for a modular mattress that overcomes at least
some of the
drawbacks of what is known in the field.
SUMMARY
[0005] The techniques described herein relate to the design and assembly of a
modular
multi-zone mattress having an optimized sleep surface defined by multiple
mattress
modules. Implementations of the modular multi-zone mattress respond to the
above-
identified need by providing each mattress module with a deformability and a
geometry
that are tailored to the individual anthropometry of each mattress user,
including at least
one of the body weight distribution and a body posture. The resulting sleep
surface
provides to the mattress user an optimized contact pressure distribution for a
given body
posture.
[0006] The present modular multi-zone mattress comprises a plurality of
mattress
modules being longitudinally and optionally laterally adjoined to define a
sleep surface
having a variable deformability, wherein a number of the mattress modules and
a
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deformability of each mattress module are tailored to a unique body shape and
weight
distribution of a mattress user, thereby providing at least one of an
optimized body posture
and contact pressure distribution over the sleep surface. The variation in the
body posture
and in the contact pressure distribution when in contact with the sleep
surface can be the
result of the combination of several pressure factors of the mattress user and
the
deformability profile of the sleep surface. The pressure factors include a
weight and a
morphologic profile of the mattress user. Optionally, the pressure factors can
further
include a sleep position of the mattress user.
[0007] In one aspect, there is provided a modular multi-zone mattress having
an
optimized sleep surface. The modular multi-zone mattress includes a plurality
of mattress
modules being adjoined to have a top surface thereof defining the optimized
sleep surface.
The optimized sleep surface has a variable deformability that provides at
least one of an
optimized body pressure response distribution and a minimized body posture
variation
(also referred to as optimized body posture), wherein a number of the mattress
modules
is selected in accordance with slope variations in a morphological profile of
a mattress
user, and wherein a deformability of each mattress module is tailored to a
body weight
distribution of the mattress user, for a given body posture.
[0008] In some embodiments, the multiple mattress modules are juxtaposed
longitudinally to form the sleep surface. In addition, a length of the top
surface of each
mattress module can be chosen in accordance with slope variations in a
longitudinal
morphological profile of the mattress user.
[0009] For example, the mattress can include at least three mattress modules
for
supporting respectively a head portion, an upper body portion and a lower body
portion of
the mattress user. Alternatively, the mattress can include at least five
mattress modules
for supporting respectively a head portion, a shoulder portion, a back
portion, a bottom
portion and a leg portion of the mattress user.
[0010] In some embodiments, the number of the mattress modules can be in
accordance with a number of inflection points encountered in a curvature of
the
morphological profile. In addition, the number of mattress modules can be in
accordance
with a number of slope variations AS in the morphological profile having a
threshold value.
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[0011] In some embodiments, the multiple mattress modules comprise at least
one end
mattress module which dimensions are chosen to meet mattress standard size
specifications. For example, the multiple mattress modules can include two end
mattress
modules.
[0012] In some embodiments, each mattress module can be of parallelepipedal
shape
having the top surface, a bottom surface, two opposed longitudinal sides and
two opposed
transverse sides. Optionally, at least one mattress module can have the length
of the top
surface differs from the length of the bottom surface. Further optionally, at
least one of the
two opposed transverse sides of at least one mattress module can be tapered at
an angle
from the top surface to the bottom surface. For example, both of the two
opposed
transverse sides of at least one mattress module can be tapered at an angle
from the top
surface to the bottom surface. For example, the angle of tapering of one
opposed
transverse side can be the same or different from the other opposed transverse
side.
Further optionally, at least one of the two opposed transverse sides of at
least one
mattress module can be inwardly or outwardly arched from the top surface to
the bottom
surface.
[0013] In some embodiments, the top surface of at least one mattress module
can be
upwardly or downwardly arched in accordance with the morphological profile of
the
mattress user in at least one of the longitudinal direction and the transverse
direction.
[0014] In some embodiments, the mattress can further include a frame structure
surrounding the plurality of mattress modules to provide further structural
cohesion. The
frame structure can include a top layer that extends along the top surface of
each mattress
module, the top layer having a thickness and material that are selected in
accordance with
a type of comfort.
[0015] In some embodiments, two adjacent mattress modules can be made of a
different
material.
[0016] In some embodiments, the unique body weight distribution is determined
based
on a morphological profile and a weight of the mattress user. Optionally, the
body weight
distribution can be determined based on the morphological profile, a weight
and a sleep
position of the mattress user.
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[0017] In some embodiments, the given body posture is a natural body posture
in
accordance with a sleep position of the mattress user.
[0018] In another aspect, there is provided a method for designing a modular
multi-zone
mattress comprising a plurality of adjoined mattress modules defining an
optimized sleep
surface. The method includes collecting data related to pressure factors of a
mattress
user, the pressure factors including a weight and a morphological profile of
the mattress
user; selecting a number of the mattress modules in accordance with slope
variations in
the morphological profile; selecting a deformability of each one of the
mattress modules
resulting in a deformability profile of the sleep surface; and determining at
least one of a
body posture and a contact pressure distribution across the sleep surface
based on the
deformability profile of the sleep surface and the pressure factors of the
mattress user.
The steps of selecting the deformability of each one of the mattress modules
and
determining the at least one of the body posture and the contact pressure
distribution are
repeated until the at least one of the body posture and the contact pressure
distribution is
optimized.
[0019] In some embodiments, the method can include determining the body
posture
based on the deformability profile of the sleep surface and the pressure
factors of the
mattress user for a given contact pressure distribution.
[0020] In some embodiments, the method can include determining the contact
pressure
distribution based on the deformability profile of the sleep surface and the
pressure factors
of the mattress user for a given body posture.
[0021] In some embodiments, the method can include determining both the body
posture and the contact pressure distribution based on the deformability
profile of the
sleep surface and the pressure factors of the mattress user.
[0022] Optionally, the body posture can be optimized when a natural body
posture is
met.
[0023] In some embodiments, the contact pressure distribution can be optimized
when
a gradient in the contact pressure provided by the sleep surface is minimized
in both
longitudinal and transverse directions.
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[0024] In some embodiments, selecting the number of the mattress modules can
include
determining a number of inflection points encountered in a curvature of the
morphological
profile. Optionally, selecting the number of the mattress modules comprises
determining
the number of occurrences for which a slope variation AS meets a threshold
value.
Optionally, the method can include selecting a length of a top surface of each
mattress
module in accordance with the slope variations in a longitudinal morphological
profile.
[0025] In some embodiments, the mattress modules comprise at least one end
mattress
module, and the method can further include adjusting a length of the at least
one end
mattress module to meet mattress standard size specification.
[0026] In some embodiments, collecting data related to the pressure factors
can include
manual measurement of a body shape of the mattress user. Alternatively,
collecting data
related to the pressure factors can include 3D-scanning of the body of the
mattress user.
Alternatively, collecting data related to the pressure factors can include
determining a total
height, an inside leg height, a hip height, an upper and lower waist height,
an axilla height,
an acromion height, a neck height, and a distance between anatomic landmarks
of the
body of the mattress user. Optionally, the pressure factors can further
include a sleep
position.
[0027] In some embodiments, selecting the deformability of each one of the
mattress
modules comprises selecting a material for each mattress module with a given
density
and mechanical properties. Optionally, the selection of the deformability for
each mattress
module can be performed among a finite number of available deformabilities.
[0028] In some embodiments, each step of the method can be performed via a
manual
assessment, a numerical analysis, a statistical model or an Al model.
[0029] In some embodiments, the method can further include determining an
optimisation factor based on the at least one of the body posture and the
contact pressure
distribution for each repetition, and selecting the deformability profile
resulting in the lowest
optimisation factor. Optionally, the optimisation factor can be function of a
rotation of the
body in at least one of a sagittal plane or transverse plane. Further
optionally, the
optimisation factor is function of a force rendered by at least one mattress
module upon
being contacted with the mattress user.
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[0030] The method can further include juxtaposing in a longitudinal direction
the
mattress modules in accordance with the selected deformability profile so as
to produce
the optimized sleep surface of the modular multi-zone mattress. Alternatively,
the method
can further include framing the juxtaposed mattress modules with a base layer,
a top layer
and side components.
[0031] In another aspect, there is provided a use of a numerical model to
design a
modular multi-zone mattress comprising a plurality of adjoined mattress
modules defining
a sleep surface. The numerical model is used to perform at least one of a
determination
of a number and dimensions of the mattress modules based on a morphological
profile of
a mattress user; a determination of a contact pressure or force distribution
over the sleep
surface based on the body weight distribution of the mattress user for a given
sleep
position; a determination of a variation in a body posture over the sleep
surface with
respect to a natural posture for a given sleep position; and a selection of a
deformability
of each selected mattress modules to provide at least one of an optimized
contact
pressure distribution and optimized body posture.
[0032] In another aspect, there is provided a use of a finite element
numerical model to
combine multiple modular mattress zones in accordance with an individual
anthropometry
of a mattress user, the finite element numerical model approximating the
number of
modular mattress zones, a shape of each modular mattress zone and a
deformability of
each modular mattress zone to provide at least one of an optimized contact
pressure
distribution and optimized body posture over the combined multiple modular
mattress
zones. In some implementations, the finite element numerical model is used to
approximate the deformability of each modular mattress zone among a plurality
of given
deformabilities. In some implementations, the finite element numerical model
is used to
approximate the shape of each modular mattress zone among a plurality of given
shapes.
[0033] While the invention will be described in conjunction with example
embodiments,
it will be understood that it is not intended to limit the scope of the
invention to such
embodiments. On the contrary, it is intended to cover all alternatives,
modifications and
equivalents as may be included as defined by the present description. The
objects,
advantages and other features of the present invention will become more
apparent and
be better understood upon reading of the following non-restrictive description
of the
invention, given with reference to the accompanying drawings.
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BRIEF DESCRIPTION OF THE DRAWINGS
[0034] Implementations of modular multi-zone mattress and related design
techniques
are represented in and will be further understood in connection with the
following figures.
[0035] Figure 1 is schematic cross-sectional view of an implementation of a
modular
multi-zone mattress along with a longitudinal morphologic profile of a
mattress user.
[0036] Figure 2 is a schematic top view of an implementation of a modular
multi-zone
mattress showing a rectangular top surface of each mattress module having a
varying
length Li.
[0037] Figure 3 is a schematic top perspective view of an implementation of a
mattress
module.
[0038] Figure 4 is a schematic top perspective view of another implementation
of a
mattress module.
[0039] Figure 5 is a schematic top perspective view of another implementation
of a
mattress module.
[0040] Figure 6 is a schematic top perspective view of another implementation
of a
mattress module.
[0041] Figure 7 is schematic cross-sectional view of another implementation of
a
modular multi-zone mattress along with a longitudinal morphologic profile of a
mattress
user.
[0042] Figure 8 is a schematic cross-sectional view of the same implementation
of a
modular multi-zone mattress as per Figure 7 in accordance with another
longitudinal
morphologic profile of a mattress user.
[0043] Figure 9 is a schematic cross-sectional view of another implementation
of a
modular multi-zone mattress including multiple rectangular mattress modules in
accordance with a longitudinal morphologic profile of a mattress user.
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[0044] Figure 10 is a schematic cross-sectional view of another implementation
of a
modular multi-zone mattress including multiple trapezoidal mattress modules in
accordance with a same longitudinal morphologic profile of the mattress user
as per Figure
9.
[0045] Figure 11 is a schematic of the general steps of a method for designing
mattress
modules and assembly of the modular multi-zone mattress.
[0046] Figure 12 is a schematic of the general steps of a method for designing
mattress
modules and assembly of the modular multi-zone mattress when using a 3D body
scan.
[0047] Figure 13 is a schematic view of a top surface of a mattress module
having a
curved contour.
[0048] Figure 14 is a front and side view of a generated 3D body shape for
male and
female mattress users.
[0049] Figure 15 is a schematic of a cross-sectional view of different
mattresses
combined with a side view of a 3D body shape of a mattress users of Figure 14
positioned
in a supine position above a sleep surface.
[0050] Figure 16 is a schematic of a cross-sectional view of different
mattresses having
a deformed sleep surface combined with a side view of a 3D body shape of the
mattress
users of Figure 14 positioned in a supine position over the sleep surface.
[0051] Figure 17 is a graphic representation of a body pressure distribution
over the
deformed sleep surface of each mattress illustrated in Figures 15 and 16.
[0052] Figure 18 is a schematic of a cross-sectional view of a mattress in a
transverse
direction (left) and in a longitudinal direction (right) with a side view of a
3D body shape of
a mattress user showing possible rotation of the body.
[0053] Figure 19 is a schematic of a cross-sectional view of a modular
mattress in a
longitudinal direction with a side view of a 3D body shape of a mattress user
in a natural
body posture maintaining horizontal alignment.
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[0054] Figure 20 is a schematic of a cross-sectional view of a modular
mattress in a
longitudinal direction with a side view of a 3D body shape of a mattress user
in a deviated
body posture resulting from a downward body rotation.
[0055] While the invention is described in conjunction with example
embodiments, it will
be understood that it is not intended to limit the scope of the invention to
these
embodiments.
DETAILED DESCRIPTION
[0056] The modular multi-zone mattress proposed herein results from the
combination
of a plurality of mattress modules defining a sleep surface of variable
deformability that is
tailored to provide an optimized deformation response to a unique body weight
distribution
of a mattress user. The modular multi-zone mattress can thus be said to have
an optimized
sleep surface. The deformability of the modular multi-zone mattress can vary
along a
longitudinal axis of the mattress and further optionally along a transverse
axis of the
mattress. Each mattress module is made of a material of given deformability,
and the
geometric distribution of the mattress modules forming the mattress defines
the
deformability distribution along longitudinal and transverse axes.
[0057] Several factors, referred to as pressure factors, can be taken into
account by the
techniques described herein to account for the deformation of the sleep
surface. These
pressure factors include a weight and a morphology of the mattress user. The
pressure
factors can further include a sleep position of the mattress user. The sleep
position is
defined by the position adopted by the person when he or she lies on the sleep
surface of
the mattress, for example on the back (dorsal decubitus) or on the side
(lateral decubitus).
[0058] The body weight distribution can be understood as a measure of the
distribution
of the body weight across the surface of the body in contact with the sleep
surface. In
accordance with the pressure factors, and thus depending on the distribution
of the body
weight for a given sleep position, pressure points of varying amplitude are
applied to the
sleep surface and cause deformation of the said sleep surface. The applied
body weight
distribution results in a contact pressure distribution across the entire
sleep surface, for a
given deformability profile of the sleep surface. It should be noted that the
contact pressure
distribution of the sleep surface in response to a given body weight
distribution applied by
the mattress user is considered herein as optimized when high-pressure points
have a
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minimized amplitude and surface, when the contact pressure (related to the
normal force)
that is provided by the deformed sleep surface to the body surface is uniform
(in
longitudinal direction alone or in both longitudinal and transverse
direction), when a
gradient in the contact pressure provided by the deformed sleep surface is
minimized,
when local shear stress is minimized, when the area of the sleep surface that
is in contact
with the mattress user is maximized, or a combination thereof.
[0059] The deformability of the sleep surface can lead to a variation in the
body posture_
Certain variations in the body posture can provide an uncomfortable feeling to
a mattress
user. For example, a rotation of the body in the traverse plane will create
more pressure
in the left or right side while in the longitudinal plane, such that a section
of the body would
be placed deeper in the mattress than it should be. Multiple other variations
in the body
posture are encompassed herein, such as a change in the curvature of the spine
or any
modification of the positioning of a body part with respect to a plane or axis
determining
the natural posture.
[0060] The present modular mattress and related method of design provides a
sleep
surface that can be tailored to minimize the variation in the body posture
with respect to a
natural body posture resulting from the sleep position of the mattress user.
For example,
minimization of the variation in the body posture can be understood as
minimizing the
rotation of the body in the transverse plan and sagittal plan (see Figure 18)
with respect
to a natural body posture (given by the sleep position). Ideally, no variation
would be
observed such that the natural body posture is maintained when the mattress
user is lying
over the sleep surface. It should be noted that the natural body posture
deriving from the
selected sleep position corresponds to an optimized body posture for which the
spine
curves correspond to the anatomic curves, which can be obtained by having the
mattress
user stand up straight naturally and comfortably, as it is shown for example
in Figure 14.
[0061] An optimized sleep surface as encompassed herein is to be understood as
a
sleep surface offering at least one of an optimized contact pressure
distribution and a
minimized body posture variation (also referred to as optimized body posture).
Such
optimized sleep surface can be considered as a "comfortable" sleep surface for
a mattress
user.
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[0062] The techniques described herein include determination of the body
weight
distribution over the sleep surface based on a unique combination of pressure
factors for
each mattress user. The number of the mattress modules, dimensions of each
mattress
module and deformability of each mattress module can then be tailored to
provide an
optimized deformation response to the determined body weight distribution for
a given
body posture.
Mattress implementations
[0063] Referring to Figures 1 and 2, the modular multi-zone mattress 2
includes multiple
mattress modules 4 (A to E) that can be juxtaposed longitudinally such that a
top surface
thereof 6 forms the sleep surface. Referring to Figure 10, at least the number
of mattress
modules 4 (A to L) can vary in response to variations in the slope of a
longitudinal
morphological profile 12 of the mattress user. More specifically, referring to
Figure 1, the
number of mattress modules 4 and a length L1 of a top surface of each mattress
module
4A to 4E can vary in response to variations in the slope of the longitudinal
morphological
profile 12 of the mattress user.
[0064] The longitudinal morphological profile as used herein can be defined by
a
longitudinal curvature of varying slope of the body surface that is in contact
with the
mattress (from head to toe). The transverse morphological profile as used
herein can be
defined by a medio-lateral curvature of the body surface that is in contact
with the
mattress. The morphological profile as used herein refers at least to the
longitudinal
curvature, and further optionally to the medio-lateral curvature, of the body
surface that is
in contact with the mattress. Each change in slope along the longitudinal
morphological
profile can translate in a change in a body pressure applied to the sleep
surface of the
mattress.
[0065] In some implementations, the number of mattress modules can be selected
according to the slope variations of the morphological profile of each
mattress user. For
example, the modular multi-zone mattress can include at least three mattress
modules
having a top surface for supporting a head portion, an upper body portion and
a lower
body portion of the mattress user. In another example, referring to Figure 1,
the modular
multi-zone mattress can include at least five mattress modules (A to E) having
a top
surface for supporting a head portion, a shoulder portion, a back portion, a
bottom portion
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and a leg portion of the mattress user. Indeed, the morphological profile of a
mattress user
can include multiple inflection points for a given sleep position, when
transitioning from
one body portion to another body portion. Thus, the mattress can include a
number of
modules that is related to the number of inflection points encountered in the
curvature of
the morphological profile. More generally, the modular multi-zone mattress can
include
any number of mattress modules that is chosen in accordance with the number of
curvature variations AS in the longitudinal morphological profile of the
mattress user. As
seen in Figure 1, AS can be defined as a slope variation in the morphological
profile
(longitudinal profile alone or in combination with transverse profile). AS can
be given a
determined AS threshold, and each time a difference in the slope of the
curvature of the
longitudinal morphological profile meets the AS threshold, or an inflection
point is found,
an additional mattress module can be provided for combination with the other
mattress
module(s) until the entire sleep surface is formed. One can therefore
understand that the
lower the AS threshold is chosen, the higher the number of mattress modules
will be for a
given morphological profile. Referring to Figure 9, one can see that the
number of
rectangular mattress modules is superior to the number of trapezoidal mattress
modules
illustrated in Figure 10.
[0066] It is noted that the number of mattress modules forming the sleep
surface of the
modular multi-zone mattress includes two end mattress modules located at
longitudinal
extremities of the mattress and at least one internal mattress module located
between the
two end mattress modules. For example, in Figure 1, the mattress modules 4A
and 4E
can be considered as the two end mattress modules. Referring to Figure 9, the
mattress
modules 4A and 4L can be considered as the two end modules.
[0067] Referring to Figures 3 and 4, each mattress module 4 can be defined as
a volume
of mattress material having a top surface 6 of parallelepipedal shape, being
substantially
planar in an undeformed state, and configured to support a body portion of the
mattress
user when lying generally horizontally on the mattress module The top surface
6 of each
mattress module is further defined by a top length Li that is taken in the
longitudinal
direction and a width W that is taken in a transverse direction. The top
length Li and the
width W of the mattress module define the size of the top surface 6 onto which
the mattress
user is lying down. This top surface 6 can also be referred to as a zone of
the sleep
surface, the sleep surface thereby including multiple zones that can have a
varying length
Li and further optionally, a varying shape.
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[0068] For a given mattress dimensions, the size and shape of each mattress
module
can be determined in accordance with the number of mattress modules. Referring
to
Figure 1, similarly to the number of mattress modules, one can see that the
length Li of
the top surface of each mattress module can be adapted to slope variations of
the
longitudinal morphological profile of each mattress user. For example, the
length Li can
be chosen in accordance with a length of each section of the longitudinal
morphological
profile having a change in slope equal or superior to the given AS threshold
or being at an
inflection point. For example, when comparing Figures 7 and 8, one can see
that the length
Li of the internal mattress modules B to D is differing in accordance with the
two different
longitudinal morphological profiles 12. It is noted that the length Li of the
first end mattress
module A (located below the head portion of the mattress user) can remain the
same for
specific morphotypes or even for all mattress users. It is further noted that
the length of
the end mattress module E can be chosen in accordance with a desired length of
the
mattress, so as to meet standard dimensions for example.
[0069] As seen in Figure 8 for example, the modular multi-zone mattress 2 can
further
include a frame structure surrounding the plurality of mattress modules 4 to
further provide
structural strength to the modular multi-zone mattress. More specifically, a
top layer 14
can extend along a top surface of each mattress module 4, a bottom layer 16
can extend
along a bottom surface of each mattress module 4, and side components 18 and
20 can
be juxtaposed to the end transverse sides of the first and last mattress
modules 4A and
4E. It is noted that the material and thickness of the top layer can be
selected to provide
a given type of comfort (e.g., firm, semi-firm, soft) to the mattress user
while maintaining
the uniform pressure response (contact pressure) provided by the combination
of the
mattress modules. It should be noted that the top surface of the mattress
modules can be
in direct contact with the mattress user; or differently, when a top layer is
used over the
top surface of the mattress modules, said top surface is not in direct contact
with said
mattress user. The sleep surface as referred to herein can therefore
correspond to the top
surface of the mattress modules or the top surface of an additional layer,
depending on
the composition of the modular mattress encompassed herein.
[0070] Optionally, the top surface of the mattress module can include curved
portions
that are adapted to further optimize the deformation response to the body
weight
distribution, for a given morphological profile of the mattress user. A first
and end mattress
module supporting a head portion of the mattress user can for example have a
convex top
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surface to serve as a pillow. Further optionally, the mattress can then
include a top layer
having a bottom surface being curved complementarily to the top surface of the
mattress
modules.
[0071] When referring to variable dimensions (also referred to as size and
shape) of
each mattress module, one should understand that at least the top length Li is
optimized
in accordance with the morphological profile of the mattress user. For
example, in addition
to the top length Li, the shape of the top surface can differ from a rectangle
and can
include curves, as seen in Figure 13, so as to be further optimized in
accordance with the
medio-lateral curvatures of the morphological profile of the mattress user.
[0072] Referring to Figures 3, 5 and 6, the bottom surface 8 of each mattress
module 4
can be shaped differently from the top surface 6. For example, a bottom length
L2 can be
different from the top length Li of the mattress module 4. For example, at
least one of the
two opposed transverse sides 10 of the mattress module 4 can be tapered at an
a angle.
Referring to Figure 3, both transverse sides can be tapered with the same
angle. Referring
to Figure 5, only one transverse side 10 is tapered at an angle. Referring to
Figure 6, both
transverse sides are tapered at an angle but the angle (al or az) is different
for each side.
It is noted that the two mattress modules located at longitudinal extremities
of the mattress
(e.g. A and E in Figures 1 and 2) can include a non-tapered end transverse
side to
accommodate standard mattress shape, as seen on Figures 4 and 5.
[0073] Tapering the internal transverse sides of the mattress modules allows
for a
gradual transition in deformability from the top surface of one mattress
module to the top
surface of the adjacent mattress module. The bottom length L2 and the angles
(ai and az)
defined by the transverse sides of the mattress module can be further
optimized in
accordance with a difference in deformability between two adjacent mattress
modules.
For example, the bigger the difference in deformability is between a first
mattress module
and a second adjacent mattress module, the more tapered the facing transverse
sides of
the first and second mattress can be. The angles are further limited by the
resulting bottom
length L2 of the mattress modules, so as to accommodate a given total length
of the
mattress.
[0074] It is noted that the width W of each mattress module is to be chosen in
accordance with a width of the overall mattress and can be generally the same
for all the
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mattress modules forming the mattress. It is noted that the width W of the
mattress
modules can further be chosen based on standard single bed dimensions. It is
further
noted that the height H of each mattress module can be generally the same for
all the
mattress modules forming the mattress so as to adapt to standard mattress
thicknesses.
It should further be noted that the height of the mattress module can account
for the
presence of a top layer and a base layer to match standard mattress
thicknesses.
Alternatively, the height of each mattress module can also be a parameter that
can vary
to optimize the deformation response to the body weight distribution of the
mattress user.
[0075] Defornnability is defined by the nature, the density, and the
mechanical properties
of the building material of the mattress module. Any known building material
in the field of
mattresses can be used to provide a desired deformability to each mattress
module, and
can include polyurethane foam (e.g., with density varying from 1.5 PCF (Pounds
per Cubic
Feet) to 5 PCF), viscoelastic foam or memory foam (e.g., with density varying
from 2.5
PCF to 6 PCF) and latex (e.g., with density varying from 3 PCF to 6 PCF). It
is noted that
several mattress modules of the modular multi-zone mattress, whether they are
juxtaposed or not, can be made of a same material or of a material having
substantially
the same density and/or mechanical properties.
Method implementations
[0076] Each mattress user is characterized by a unique combination of weight
and
morphology defining ergonomic needs that cannot be fully matched by a sleep
surface
designed based on general anthropometry only. The present modular multi-zone
mattress
is configured to take into account the weight and the morphology of each
mattress user.
Optionally, in addition to weight and morphology, sleep position of the
mattress user
(including supine position, prone position and lateral position) can be
considered as
another pressure factor impacting the general distribution of body weight
applied to the
sleep surface, and a depth of each of these pressure points.
[0077] The techniques described herein include collecting data related to the
morphological profile of the mattress user and selecting a number of mattress
modules in
accordance with slope variations in the morphological profile for a given
sleep position.
Once the number of mattress modules is determined, the deformability of each
mattress
module can be selected in accordance with the body weight distribution for a
given
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mattress user so as to create the optimized sleep surface as defined herein.
Thus, each
mattress module has a deformability tailored to a specific body pressure range
imposed
by the mattress user. For example, the selection of deformability for each
mattress module
can be performed to provide an overall sleep surface having an enhanced
contact
pressure profile (compared to a mattress of unique deformability and lacking
the modular
configuration).
[0078] Referring to Figures 11 and 12, a first step (step 1) of the method is
the collection
of data related to the pressure factors of the mattress user. Such pressure
factors include
the weight of the mattress user and a morphology of said user. Collecting data
related to
the morphology of the mattress user can be performed in various ways including
manual
measurements of a body shape of the mattress user, and 3D-scanning of the body
of the
mattress user. For example, measurements of the body shape can include
measuring a
total height, inside leg height, hip height, upper and lower waist height,
axilla height,
acromion height, neck height and distance between anatomic landmarks. The
measurements can further include width and thickness at each of these anatomic
landmarks (excepted for a total height). The measurements can further include
a
circumference at each of these anatomic landmarks. It should be understood
that the
minimal data required are measurements providing the weight and a satisfying
morphological profile of the mattress user, so as to produce a body weight
distribution and
a correlated body pressure distribution including maximal pressure points.
[0079] Still referring to Figures 11 and 12, the method further includes
selecting the
number of the mattress modules and dimensions of each mattress module based on
the
morphological profile (step 2). Optionally, selecting dimensions of each
mattress module
can include selecting a length L1 of the top surface of each mattress module.
Further
optionally, selecting dimensions of each mattress module can include selecting
a shape
of the top surface of each mattress module.
[0080] The selection of the number and dimensions of the mattress modules can
be
performed in various ways including visual analysis or numerical analysis. For
example,
referring to Figure 1, the number and dimensions of the mattress modules 4 can
be
selected via a visual analysis of the morphological profile 12 by locating
inflection points
(or slope variations that would be equal or superior to a slope variation
threshold) in the
longitudinal morphological profile. Alternatively, the combination of the
number and
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dimensions of each mattress module can be determined via a numerical analysis
based
on a mathematical (numerical) model enabling automatic calculation of these
variables
based on the morphological profile of the mattress user.
[0081] The method can include selecting a length of the last end mattress
module in
accordance with a desired length of the sleep surface of the mattress. The
length of the
last end mattress can simply be obtained by subtracting the length of the
remaining
mattress modules to a total desired length.
[0082]
Still referring to Figure 11 and 12, the method further includes selecting
a
deformability of each mattress module based on the body weight distribution
for a given
mattress user (step 3). Selecting the deformability can be assimilated to
selecting a
material of given nature, density and mechanical properties for each mattress
module. It
should be noted that the selection of the deformability of each one of the
mattress modules
can be tailored to provide an optimized contact pressure distribution for a
given body
posture, an optimized body posture for a given contact pressure distribution,
or a
combination of both.
[0083] The selection of the deformability of each one of the mattress modules
to provide
at least one of the optimized contact pressure distribution and the optimized
body posture
can be performed in various ways, including manual assessment and numerical
analysis_
[0084] For example, the numerical analysis can be the result of an analytical,
statistical
or finite element model. Each of these numerical models can be used to
associate the
weight of the mattress user to the corresponding morphological profile to
determine a body
weight distribution of the body surface in contact with the sleep surface of
the mattress,
and then to generate the contact pressure distribution over the sleep surface
for a given
combination of mattress modules. The numerical model can be further used to
select a
deformability for each of the determined number of mattress modules so as to
form a sleep
surface having a varying deformability profile that provides an optimized
contact pressure
distribution. For example, the resulting sleep surface has a varying
deformability profile
that is selected to produce a surface pressure response of enhanced uniformity
when the
body weight distribution of the mattress user is applied thereto.
[0085] The selection of the deformability can include selecting a density of
the building
material of the mattress module. It is noted that the selection of the
deformability for each
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mattress module can be performed among a finite number of available
deformabilities. For
example, the numerical model is run as a loop that will end when a combination
of selected
deformabilities for the mattress modules satisfies a given uniformity
criterion or
optimisation factor corresponding to the pressure response of the sleep
surface (optimized
contact pressure distribution), the optimized body posture, or both. More
particularly, the
numerical model can be given densities of available building material and the
selection of
the deformability can include selecting a building material of given density.
Additional
mechanical properties of the building material, such as Young modulus, Poison
ratio, bulk
modulus, shear modulus, viscoelastic parameters, stress-strain curves, or a
combination
thereof can be used as input data of the numerical model to assist in the
selection of an
optimized deformability profile.
[0086] In some implementations, the selection of the deformability profile for
a given
body weight distribution can be performed based on a numerical model including
the use
of a mathematical expression that evaluates the performance of different
combinations of
mattress modules of given deformability based on an optimisation factor taking
into
account at least one of the maximal force provided by a mattress module (e.g.,
shoulder
module) and the variation of the body posture (e.g., rotation). The numerical
model
compares the performance of one mattress with respect to multiple other
mattresses, and
selects the mattress having the smallest optimization factor (best
performance). For
example, in below Equation (1), each mattress (i) is compared to the other n
mattresses
using a normalized function taking into account the normalized maximal forces
of three
different mattress modules (shoulder module, lumbar module and pelvic module).
The
smallest resulting optimization factor will correspond to the modular mattress
having the
lowest maximal forces at the shoulder and pelvis module, and the highest
maximal force
at the lumbar module (as lumbar curve is not always in contact with the sleep
surface).
Imposing the highest force at the lumbar module allows to maximize the contact
of the
sleep surface with the lumbar region of the body, such that the contact
pressure
distribution is optimized.
Equation (1)
Optimisation f actort
2
i 2
= ( F orceShoulderBloci F orce Lumbar Bloc; F orceP
elvisB loci )2
__________________________________ (1 ________________
i-riax (ForceShoulderBloci_õ)) max (ForceLumbarBloci_õ)) + (max (F
orceP eivisBloci_õ))
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[0087] The numerical model can be adapted to evaluate the sleep surface based
on
another criteria, that is the minimization of the variation in the body
posture with respect
to the natural body posture given by the sleep position. For example, in below
Equation
(2), each mattress (i) is compared to the other n mattresses using a
normalized function
taking into account the rotation energy of the chest in the sagittal plane.
The smallest
resulting optimization factor will correspond to the modular mattress having
the smallest
rotation energy (optimized body posture).
Equation (2)
( Rotation energy, )
Optimisation factor, = _________________________________________
max (Rotation energyi_õ))
[0088] The numerical model can be further adapted to evaluate the sleep
surface based
on all of the above criteria. For example, in below Equation (3), each
mattress (i) is
compared to the other n mattresses using a normalized function taking into
account the
rotation energy of the body, and the normalized forces of three different
mattress modules
(shoulder module, lumbar module and pelvic module). The smallest resulting
optimization
factor will correspond to the modular mattress having the smallest rotation
energy
(optimized body posture), the lowest forces at the shoulder and pelvis module,
and the
highest force at the lumbar module (as lumbar curve is not always in contact
with the sleep
surface).
Equation (3)
( Rotation energyi )2
ForceShoulderBloci )2
max(Rotation energyi_,)) max(ForceShoulderBloci_n))
Optimisation factor. =
2
ForceLumbarBloct ForcePelvisBloci )2
+ (1 max (ForcelaimbarBloci_õ)) + (max (ForcePelvisBloci_,))
[0089] It should be noted that a same numerical model having the weight and
morphological profile as input data can be established to perform
determination of the
number and dimensions of the mattress modules based on the morphological
profile,
determination of the at least one of the contact pressure distribution and the
body posture
based on the weight and the morphological profile, and selection of the
deformability of
each selected mattress modules to provide an optimized sleep surface.
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[0090] Other ways to select the deformability of each one of the mattress
modules and
provide an optimized sleep surface can include the use of a statistical model
that uses the
morphology of a given mattress user and compares it to a data bank of
combinations of
mattress modules for known mattress users to generate a combination of
mattress
modules (number, dimensions and deformability) that is tailored to the given
mattress
user. The data bank includes information related to the weight, morphology and
related
modular multi-zone mattress for past mattress users. Another possibility to
build the
optimized modular mattress for a specific morphology is to use a trained
artificial
intelligence (Al) model. The Al model can be trained to determine, based on
existing
association of morphologies and mattress module deformabilities, the best
material for a
given morphology and weight. The Al model can be periodically or continuously
retrained
as new morphologies and material characteristics are added to the databases.
[0091] It should however be noted that selection of the deformability for each
mattress
module can be performed manually. For example, one could combine the
determined
number of mattress modules with given deformability and assess at least one of
the
contact pressure distribution and the body posture when the mattress user is
in a given
sleep position. If the contact pressure distribution or the body posture is
not considered
as optimized (large gaps between body and sleep surfaces or pressure points
felt by the
mattress user, excessive rotations), the number and/or material of the
mattress modules
could be varied until a satisfactory and optimized sleep surface is found.
[0092] It should further be noted that certain steps of the method described
herein can
be performed manually while other can be performed with the assistance of a
numerical
analysis, a statistical model or an Al model. For example, selection of the
deformability of
the mattress modules can be performed manually while the determining of at
least one of
the resulting body posture and contact pressure distribution can be performed
via
numerical simulation.
[0093] Referring to Figures 11 and 12, the method then includes juxtaposing in
a
longitudinal direction, and optionally in a transverse direction, the mattress
modules in
accordance with the determined deformability profile so as to produce the
sleep surface
of the modular multi-zone mattress (step 4). Optionally, referring to Figure
8, the method
can finally include framing the juxtaposed mattress modules 4 with the base
layer 16, a
top layer 14 and the side components 20.
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[0094] It should be noted that the method can include performing the steps as
defined
above for more than one mattress user, e.g., two mattress users, and combine
the
selected mattress modules so as to form a two-people modular multi-zone
mattress having
two different optimized sleep surfaces distributed transversally.
[0095] It should be noted that the same numerical references refer to similar
elements.
Furthermore, for the sake of simplicity and clarity, namely so as to not
unduly burden the
figures with several references numbers, not all figures contain references to
all the
components and features, and references to some components and features may be
found in only one figure, and components and features of the present
disclosure which
are illustrated in other figures can be easily inferred therefrom. The
embodiments,
geometrical configurations, materials mentioned and/or dimensions shown in the
figures
are optional, and are given for exemplification purposes only. Therefore, the
descriptions,
examples, methods and materials presented in the claims and the specification
are not to
be construed as limiting but rather as illustrative only.
[0096] Although the implementations of the modular multi-zone mattress and
corresponding parts thereof consist of certain geometrical configurations as
explained and
illustrated herein, not all of these components and geometries are essential
and thus
should not be taken in their restrictive sense. Moreover, it will be
appreciated that
positional descriptions such as "above", "below", "first", "last" and the like
should, unless
otherwise indicated, be taken in the context of the figures and should not be
considered
limiting.
[0097] In the above description, an implementation or embodiment is an example
of the
invention. The various appearances of "one embodiment," "an embodiment" or
"some
embodiments", "an implementation", "some implementations" do not necessarily
all refer
to the same example. Although various features of the invention may be
described in the
context of a single implementation, the features may also be provided
separately or in any
suitable combination. Conversely, although the invention may be described
herein in the
context of separate implementations for clarity, the invention may also be
implemented in
a single implementation.
[0098] It should be understood that any one of the above-mentioned optional
aspects of
each the mattress, designing method and use of a model to design the mattress
may be
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combined with any other of the aspects thereof, unless two aspects clearly
cannot be
combined due to their mutual exclusivity. For example, the various operational
steps of
the method described herein-above, herein-below and/or in the appended
Figures, may
be combined with any description of the structural elements of the mattress
appearing
herein and/or in accordance with the appended claims.
EXAMPLES
[0099] Two examples of stress distribution (corresponding to the contact
pressure
distribution at the interface between the sleeper and the top surface of the
mattress) for 3
different mattresses for two mattress users are provided below.
Mattress users presentation
[00100] Two mattress users with different morphological body shape (profile)
and weight
were studied. The morphological body shape of each mattress user was obtained
with a
3D scanner, while the weight was obtained with a scale. The corresponding
front and side
views of the collected morphological body shape of a male mattress user and a
female
mattress user are seen in Figure 14.
Mattresses description
[00101] Referring to Figure 15, three different mattress designs (1, 2, 3A and
1, 2, 3B)
were tested for each mattress user. Accordingly, three different contact
pressure
distributions were obtained. Mattress 1 is a standard type mattress as readily
known in the
art including a base layer, an intermediate support layer and a top comfort
layer.
Mattresses 2, 3A and 3B correspond to mattresses as encompassed by the
implementations described herein.
[00102] Each letter represents a specific material for the mattress module. In
this
example, mattresses 1 and 2 are composed of the same materials for both
mattress users.
Mattress 3A differs from mattress 3B in terms of module dimensions and
materials for
each mattress user.
Mattresses performances
= Body support
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[00103] Referring to Figure 16, when visually assessing the support provided
to the
longitudinal morphological profile of the mattress users, one can observe that
mattress 2
does not provide enough support in the lumbar region. Indeed, there is a gap
(no contact)
between the back and the sleep surface for both mattress users. Little or no
contact
between the mattress user and the sleep surface creates high-pressure zones at
the
sleeper-bed interface where the body is in contact with the mattress. For
example, if there
is no contact in the lumbar region, the contact pressure will be higher in the
thoracic and
sacral regions. VVhen comparing mattress 3A or3B with mattress 2, the presence
of lumbar
gap demonstrates that the shape and the material that compose the mattress
modules
impacts the optimization of the contact pressure distribution
= Optimized contact pressure distribution
[00104] Figure 17 shows the pressure mapping over the sleep surface in
response to the
application of the body weight distribution of the mattress user for each of
mattresses 1,
2, 3A and 3B. For both mattress users, mattress 1 induces higher contact
pressure
regions in the contact pressure distribution than the other mattresses. With
mattress 2,
higher contact pressure regions are reduced, but some areas of the contact
pressure
distribution (corresponding to a change of module and material) still present
large contact
pressure variation. Mattress 3A and 3B provide the lowest contact pressure
regions and
the contact pressure gradients are minimized in comparison to the other
mattresses. One
can thus see that the optimization of the contact pressure distribution at the
interface
between the mattress user and the sleep surface is better for mattress 2, 3A
and 3B
(having longitudinal distribution of mattress modules) than for mattress 1,
and that the
optimization of the contact pressure distribution is even better for
mattresses 3A and 3B
(having tapered mattress modules) than for mattress 2.
= Minimized variation in the body posture
[00105] Figure 19 shows a side view of a 3D modelisation of a body that lies
in a back
sleep position on the present modular mattress having an optimized sleep
surface that
maintains the natural body posture or at least minimize the variations in the
body
alignment. As can be seen on Figure 19, the natural posture follows a
substantially
horizontal axis when the mattress user lies down. The selected combination of
mattress
modules of trapezoidal shape shown in Figure 19 can provide an optimized body
posture
to the mattress user in the sense that the mattress can maintain the natural
body posture
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in a given sleep position, differently to the combination of mattress modules
shown in
Figure 20 where the body posture is allowed to slightly vary via a rotation of
the shoulders.
This rotation occurs by the fact that the material is softer at the shoulders
for the second
mattress. Minimizing variations in the body posture with respect to the
natural body
posture can have a role in the comfort evaluation but also in providing an
adequate spine
support.
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